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1. The breaker plate should move counterclockwise and clockwise freely when you do this repeatedly If you suck and then cover the vacuum port with your tongue the vacuum advance plate should stay in the same position until you lift your tongue If it drifts back before you lift your tongue the diaphragm is leaking and it won t advance the timing properly In that case you need to replace the vacuum canister or the entire distributor Hot Spark Ignition and MSD 6 Series Wiring Diagram www Hot Spark com Hot Spark MSD 6 series jpg Volvo 1800 with Tachometer and Hot Spark Wiring Diagram www Hot Spark com Volvo 1800 Wiring Diagram htm Porsche 911 CDI Box Wiring Diagram www Hot Spark com Porsche 911 CDI Wiring Diagram jpg Latest On Line Installation Instructions www Hot Spark com Installing Hot Spark Bosch pdf Measuring Coil Resistance www HotSpark com Coil htm Problems with Installation See www Hot Spark com Troubleshooting pdf A printable VW Type I crankshaft pulley degree wheel template for the SVDA 034 www Hot Spark com Hot Spark S VDA034 V W Type I Pulley Degree Template pdf A printable VW Type I crankshaft pulley degree wheel template for the 009 distributor www Hot Spark com Hot Spark 009 V W Type I Pulley Degree Template pdf 2005 2015 HotSpark 7 2005 2015 HotSpark2. by measuring clockwise from top dead center around the circumference of the pulley 45 8 mm or 1 13 16 in Make a small white paint mark there That s about 30 BTDC Timing a Stock Air Cooled VW Vacuum advance Distributor A stock vacuum advance distributor should be timed with a stroboscopic light and tach dwell meter according to the specifications in the VW service manual Static timing using an ordinary 12 volt test lamp will not work For dual vacuum advance distributors with vacuum canisters having two vacuum ports You can locate the 5 ATDC spot on a stock VW Type I crankshaft pulley which has a 175 mm 6 7 8 in diameter by measuring counterclockwise from TDC around the circumference of the pulley 7 6 mm 5 16 in Paint a small white mark here This is about 5 ATDC the point at which the dual vacuum advance distributor its vacuum canister has two vacuum ports 1s usually timed at idle Refer to the official VW Service Manual for the proper timing specifications for the distributor used in your vehicle For SVDA single vacuum dual advance distributors You can locate the 7 5 BTDC spot on a stock VW Type I crankshaft pulley which has a 175 mm 6 895 in diameter by measuring clockwise to the right from TDC around the circumference of the pulley 11 45 mm 7 16 in Paint a small white mark here This is the point at which the centrifugal advance 009 and certain single vacuum dual advance SVDA distrib
3. distributors Fits both vacuum advance and centrifugal advance only distributors with one piece right hand points Installs same as 3BOS4C1 but has smaller footprint and shorter magnet sleeve To increase air gap slightly hold ignition base plate away from distributor shaft while tightening set screw and or loosen the two Allen head screws and retighten screws while lightly prying ignition module away from magnet sleeve Do not over torque these Allen screws 3BOS4U2L supersedes 3BOS4U1L Universal ignition kit for 4 cylinder Bosch distributors with one piece left hand points Fits both vacuum advance and centrifugal advance only distributors Installation is similar to 3BOS4U1 3BOS4V2 Ignition kit for early 4 cylinder Bosch vacuum advance distributors with two piece right hand points Installation is similar to 3BOS4U1 Before installing ignition module or magnet sleeve install an 8mm 5 16 O D round rubber grommet in the round hole in the side of the distributor body for the two wires to pass through Push pull the wires through the grommet from the inside out Solder or crimp tightly connectors on the wire ends 3BOS6U1 supersedes 3BOS6V1 Universal ignition kit for 6 cylinder Bosch distributors with one piece right hand points Fits both vacuum advance and centrifugal advance only distributors Installation is similar to 3BOS4U1 After you remove the points a 16mm box end wrench should fit easily over the distributor shaft lobes If th
4. not critical In rare instances it may be necessary to gently pry red ignition module away from black magnet sleeve to keep them from rubbing together Ignition Timing Set the ignition timing with a stroboscopic light to the distributor s factory specification The difference in distributor position with points vs electronic ignition can be as much as 30 degrees or so clockwise or counterclockwise so you ll definitely have to reset the timing Wiring Installation Basics 1 Remove points condenser and condenser wire from the vehicle 2 Attach the red lead of a voltmeter to the coil s positive or 15 terminal Attach the voltmeter s black lead to engine ground With the ignition switch on engine not running measure the voltage at the coil s positive or 15 terminal The reading should be somewhere around 11 to 13 volts If voltage 1s too low or there s no reading the battery s terminals or ground connection may be corroded and need cleaning Some vehicles have a resistor wire running from the ignition switch to the coil s terminal If this resistor wire drops the voltage below 9 volts you may need to run a non resistor wire from the ignition switch to the coil s terminal or run a 12V wire directly from the ignition switch to the red Hot Spark ignition wire Make sure that the ignition switch terminal to which you connect this wire has power only when the ignition switch is in the ON position To get the ignition runni
5. the voltage measures more than 14 0 volts you ll need to replace the voltage regulator install a coil with 3 Ohms or more internal primary resistance or install a 1 4 Ohm external ballast resistor between the ignition switch and the coil s terminal Test Battery Voltage to Coil With ignition switch ON engine not running check voltage at coil s terminal The voltmeter should read somewhere around 11 to 13 volts If voltage is too low or there s no reading the battery s terminals or ground connection may be corroded and need cleaning or the battery may need charging Some vehicles have a resistor wire running from the ignition switch to the coil s terminal If this resistor wire drops the voltage below 9 volts or so you may need to run a non resistor wire from the ignition switch to the coil s terminal or run a 12V wire directly from the ignition switch to the red Hot Spark ignition wire Make sure that the ignition switch terminal to which you connect this wire has power only when the ignition switch is in the ON position Air Gap between Magnet Sleeve and Ignition Sensor If you need to increase air gap slightly hold ignition base plate away from distributor shaft while tightening set screw and or loosen the two Allen head screws and retighten screws while lightly prying ignition module away from magnet sleeve Do not over torque these Allen screws Black magnet sleeve should not rub against red ignition module but exact gap is
6. W LUJ SPARE PERFORMANCE PRODUCTS f Installing the Hot Spark Electronic Ignition Conversion Kit in Bosch Distributors Warning Reversing the red and black ignition wires will destroy the ignition module The Hot Spark module s red wire connects to positive or 15 on Bosch coil The black wire connects to negative or 1 on Bosch coil Remove the condenser and its wire from vehicle Connect any other wires to the coil in their original positions This module is designed for 12V negative ground applications only Make sure that the ignition wires have plenty of slack inside the distributor and are not rubbing on any moving parts It s best to use a small plastic zip tie on the inside of the distributor where the ignition wires exit to keep the wires from being accidentally pulled into contact with moving parts If you need to extend the length of the ignition wires use 20 gauge AWG wire Solder or crimp tightly all connections Ren Wite to distributor cap from Hot Spark Module or 15 or 1 Yeah og a a a 4 i A n Hot Wire Black Wire from from Ignition Hot Spark Switch Module Remove points condenser and condenser wire from distributor Remove the condenser and its wire from the vehicle Important Clean the distributor s breaker points plate thoroughly so that the ignition module s base plate makes good thermal contact with the distributor Coil 4 Cylinder Coil must have a minimum of 3 0 Ohms p
7. connect the battery and set the distributor timing statically 13 You can set the timing statically to about 0 TDC at first so that the engine will start You may need to turn the distributor a little at a time right or left to enable the engine to start and remain running Time the engine with a stroboscopic light in the normal manner Setting Timing This will probably be the last time you have to set the timing for a long time so it s worth it to spend the extra time and effort to set the timing absolutely spot on accurately An engine with its timing set to perfection will start with the slightest bump of the starter and purr like a kitten at idle something to make you feel good every time you start the engine TDC Top Dead Center or 0 BTDC Before Top Dead Center ATDC After Top Dead Center 5 2005 2015 HotSpark It s hard to say which distributor an old air cooled VW actually has in place The original stock distributor could very well have been replaced with a different distributor over the years Bosch distributors for VW have a Bosch number on a badge or stamped onto their sides similar to 0 231 XXX XXX Distributors may also have a VW number which is preceded by a VW and maybe an Audi symbol It s most useful to find the Bosch number and look up the timing specifications for that particular VW distributor here External link www oldvolkshome com ignition htm Finding Timing Marks on Type I VW Engine B
8. e lobes are larger than that you may need to order the 18 6mm I D magnet sleeve for Bosch 6 cylinder distributors 3 BOS6U3 3BOS6U2L supersedes 3BOS6U1L Universal ignition kit for 6 cylinder Bosch distributors with one piece left hand points Fits both vacuum advance and centrifugal advance only distributors Installation is similar to 3BOS4U1 After you remove the points a 16mm box end wrench should fit easily over the distributor shaft lobes If the lobes are larger than that you may need to order the 18 6mm I D magnet sleeve for Bosch 6 cylinder distributors 3BOS6U3L 3BOS4C2 Ignition kit for early 4 cylinder Bosch non vacuum advance distributors with two piece right hand points Installation is similar to 3BOS4U1 Before installing ignition module or magnet sleeve install an 8mm 5 16 O D round rubber grommet in the round hole in the side of the distributor body for the two wires to pass through Push pull the wires through the grommet from the inside out Solder or crimp tightly connectors on the wire ends 3BOS6C2 Ignition kit for early 6 cylinder Bosch non vacuum advance distributors with two piece right hand points Installation is similar to 3BOS4U1 Before installing ignition module or magnet sleeve install an 8mm 5 16 O D round rubber grommet in the round hole in the side of the distributor body for the two wires to pass through Push pull the wires through the grommet from the inside out Solder or crimp tightly connec
9. eetle Ghia Thing pre 1972 Bus etc There are several different versions of stock crankshaft pulleys that came with Type I VW engines over the years each having its own set of notches timing marks in different places relative to TDC very confusing Like the distributor the pulley may have been swapped out several times over the years so you don t know what the notches on it mean Locate Top Dead Center 0 or TDC There should be a notch in the crankshaft pulley wheel at TDC aligned with where the crankcase halves join You can copy and cut out the pulley wheel degree template on the last page of these instructions to find 7 5 30 40 BTDC etc Timing the Bosch 009 or 050 Centrifugal Advance Distributor VW or Porsche only Use a stroboscopic timing light regardless of whether the distributor is equipped with points or an electronic ignition module Static timing at around 7 TDC is suitable only for the initial adjustment in order to get the engine running To set the timing accurately you must use a stroboscopic light connected to No 1 cylinder s spark plug wire Set the timing with the engine running at 3 500 RPM so that the timing 1s fully advanced The 009 s timing should usually be set no further advanced than 30 32 BTDC at 3 500 RPM Static timing using an ordinary 12 volt test lamp will not work You can locate the 30 BTDC spot on a stock VW Type I crankshaft pulley which has a 175 mm 6 7 8 in diameter
10. ng initially only these wires should be attached to the coil s 15 and 1 terminals A 12 volts from the ignition switch to the coil s terminal B Red Hot Spark wire to the coil s terminal C Black Hot Spark wire to the coil s terminal DO NOT connect any 12 volt wire to the coil s terminal Connect only the black Hot Spark ignition wire to the coil s terminal D The automatic choke and fuel shut off valve may also need to be attached to the coil s terminal E Generally only the black Hot Spark wire is attached to the coil s terminal If a tachometer wire is usually attached to the coil s terminal don t attach it until the timing has been set and engine is running properly No other wires should be connected to the coil s and terminals at this time 2 2005 2015 HotSpark F Static timing using an ordinary 12 volt test lamp will not work Attach a stroboscopic timing light to the spark plug wire of cylinder number With engine rotated to TDC 0 degrees on the firing stroke of Cylinder number 1 ignition switch ON turn the distributor until the timing light flashes You may need to turn the distributor left or right a little at a time until the engine will stay running so that you can set the timing with the engine running using a stroboscopic timing light according to factory specifications G For testing purposes no other wires should be attached to the coil terminals except for the center high ten
11. rimary resistance 6 Cylinder Coil must have a minimum of 1 5 Ohms primary resistance The Bosch blue coil 00012 has a little more than 3 Ohms primary resistance The HS34HEC high energy coil and Beru Blue Coil 3 3 Ohms primary have sufficient resistance for 4 cylinder applications The HS17HEC high energy coil has 1 7 Ohms primary resistance To measure primary resistance Label and remove all wires to coil or Using a common digital multimeter in the 200 Q mode cross the red and black leads of the Ohmmeter Allow a few seconds for the reading to settle and record it l 2005 2015 HotSpark Still in the 200 Ohm mode measure between coil s and terminals Allow a few seconds for the reading to settle until it stabilizes Subtract the previous reading taken with the leads crossed to compensate for multimeter s inherent resistance Do not use a low resistance coil such as the MSD or Accel coil they don t have enough primary resistance for this application Using a coil with too little primary resistance can cause the ignition module to overheat and misfire until it cools down again or fail voiding the warranty For best performance the coil should also have 7 000 Ohms or more secondary resistance measured from coil s or terminal to center high tension terminal in the 20K Q mode of the Ohmmeter Test Charging Voltage to Coil Check the voltage reading at the coil s terminal engine running at 2 500 RPM If
12. sion lead to the distributor cap Attach a stroboscopic timing light to the spark plug wire of Cylinder number 1 With engine rotated to TDC on the firing stroke of Cylinder number 1 ignition switch ON slowly turn the distributor clockwise or counter clockwise until the timing light flashes Tighten the distributor clamp a little so that you can still turn the distributor by hand but the distributor won t turn on its own The rotor should be pointing to number 1 cylinder s spark plug wire Start the engine You may need to turn the distributor left or right a little until the engine will stay running so that you can set the timing with the engine running using a stroboscopic timing light according to factory specifications Detailed Installation Instructions 1 Turn off the ignition switch and or remove the ground strap from the battery Though not absolutely necessary it is probably easiest overall to remove the distributor from the car before installing the Hot Spark module If the contacts in the inside of the distributor cap are worn or damaged replace the distributor cap Replace the rotor if it s worn 2 Remove distributor cap leaving the plug wires in place unless replacing the distributor cap as well 3 Remove points condenser and the condenser s wire from the vehicle Because the Hot Spark kit does not modify the distributor the points and condenser can be reinstalled at a later time 4 Clean any grease or dirt thoro
13. talled you should be able to rotate the distributor shaft without the distributor cap wobbling If the distributor cap still wobbles you may need to adjust the number or thickness of the distributor shaft shims especially if you re installing the ignition in a Chinese knockoff 009 distributor 8 Adjust the two Hot Spark ignition wires so that they have plenty of slack inside the distributor and they re not rubbing on any moving parts You can secure the two ignition wires with a small plastic zip tie inside the distributor just next to where the wires exit 9 Install the distributor cap 10 Reinstall the distributor Be sure that the anti chatter spring is in place in the distributor drive gear in the bottom of the distributor shaft hole 11 The Hot Spark module s red wire connects to positive or 15 on Bosch coil The black wire connects to negative or 1 on Bosch coil DO NOT reverse the polarity of these wires or the ignition module will be destroyed 12 Check all wire connections including the two Hot Spark wires and the spark plug and coil high tension wires If you need to extend the length of the wires use 18 or 20 gauge wire We recommend soldering all splices and connections if you can or crimp all connections tightly Make doubly sure that all wires are connected to the proper terminals etc before reconnecting the battery or turning the ignition switch to the ON position Make sure that all connectors are snug Re
14. the the rotor on top of that and tap gently on the center of the rotor to seat magnet sleeve fully Magnet sleeve fit too loose If the fit between the distributor shaft lobes and the magnet sleeve is too loose the distributor shaft may be worn down from years of the points block rubbing on the distributor cam lobes with accumulated dirt and grit and or insufficient lubrication If the fit is especially loose the only solution short of replacing the distributor may be to clean the distributor cam lobes thoroughly with alcohol and wrap the lobes with a single wrap of high quality electrical tape before pressing the magnet sleeve down over the lobes Too loose a fit between magnet sleeve and distributor cam lobes may result in erratic timing Magnet sleeve positioned too high Situation The fit between the distributor shaft and the magnet sleeve is especially tight and you can t slide the magnet sleeve down onto the distributor shaft all the way The rotor rides too high causing the distributor cap to wobble when you rotate the distributor shaft Fix Rotate the magnet sleeve so that it lines up with the lobes of the distributor shaft cam and the magnet sleeve can slide down a bit Install the rotor and tap with the butt of a screwdriver a small hammer or a soft rubber mallet very gently on the center of the rotor until the magnet sleeve seats firmly onto the distributor shaft over the distributor cam lobes With the rotor and distributor cap ins
15. tors on the wire ends After you remove the points a 16mm box end wrench ring spanner should fit easily over the lobes of the distributor shaft 3BOS6V2 Ignition kit for early 6 cylinder Bosch vacuum advance distributors with two piece right hand points Installation is similar to 3BOS4U1 Before installing ignition module or magnet sleeve install an 8mm 5 16 O D round rubber grommet in the round hole in the side of the distributor body for the two wires to pass through Push pull the wires through the grommet from the inside out Solder or crimp tightly connectors on the wire ends After you remove the points a 16mm box end wrench ring spanner should fit easily over the lobes of the distributor shaft 4 2005 2015 HotSpark 7 Install magnet sleeve with the larger opening down Turn the magnet sleeve left and right while pushing down firmly until you can feel the distributor shaft cam lobes line up with the flat spots inside the magnet sleeve Press down firmly until the magnet sleeve slides as far down as it will Install the rotor on top of the magnet sleeve making sure the rotor is aligned with the slot in the top of the distributor shaft The rotor should slide all the way down and lock into place so that it cannot turn independently of the distributor shaft If you can still turn the rotor independently of the distributor shaft the magnet sleeve and or rotor is not seated all the way down You may need to install magnet sleeve
16. ughly from the distributor s points cam and the breaker points plate 5 Insert the Hot Spark module s wires one at a time from the inside of the distributor out through the hole in the side of the distributor Gently pull and rock up and down and side to side the rubber grommet halfway through the hole until it seats 6 Clean the breaker plate thoroughly to provide a solid electrical ground and good thermal transfer You can apply a very thin coat of thermal transfer grease to the bottom of the ignition base plate Place the Hot Spark module s bottom plate onto the distributor s breaker plate The peg should fit snugly into the hole in the breaker plate and the screw holes should line up The Hot Spark module s base plate should lie flat and snug on the distributor s breaker plate Insert the screw and tighten while gently pressing the ignition module away from the distributor shaft i a Left 3BOS4U1 in distributor with I piece right hand points Center 3BOS4C2 in 010 non vacuum distributor with 2 piece right hand points Right 3BOS4V2 in vacuum advance distributor with 2 piece points 3 2005 2015 HotSpark fe Bie E tie pleted die hwb es mon So imna Left 3BOS4U1 for 1 piece right hand points Center 3BOS4U2L for 1 piece left hand points Right 3BOS4V2 for vacuum advance distributor with 2 piece right hand points 3BOS4U1 supersedes 3BOS4V1 and 3BOS4C1 Universal ignition kit for 4 cylinder Bosch
17. utors their vacuum canister has only one vacuum port are timed at idle Again refer to the official VW Service Manual for the proper timing specifications for the distributor used in your vehicle Spark Plug Gap With the Hot Spark ignition kit the stock spark plug gap specification is fine For racing purposes you can increase the spark plug gap by about 005 inches or 12 mm Rubber Grommet The 3BOS4U1 and 3BOS6U1 have the larger square rubber grommet for later Bosch distributors If your distributor uses the earlier smaller round grommet you ll need to replace the square grommet with a 3 16 round grommet Cut off the ignition module s 1 4 female connectors Pass the wires from the inside of the distributor out through the round hole in the side of the distributor body and then through the round rubber grommet Seat the grommet in the hole Crimp or solder new 1 4 female connectors onto the ends of the wires Make sure that the wires have plenty of slack inside the distributor and won t rub on moving parts It s a good idea to install a small plastic zip tie around the red and black wires where they exit on the inside and outside of the distributor to keep the wires from being pulled accidentally into contact with moving parts inside the distributor 6 2005 2015 HotSpark Testing Vacuum Advance Mechanism If your engine has a vacuum advance distributor test the vacuum canister by sucking hard on its vacuum port
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